We are REALLY excited to talk paper vs. plastic!

We are REALLY excited to talk paper vs. plastic!We love packaging!

(C) Dordan Manufacturing Co. Inc. 2011

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Paper vs. Plastic


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Paper feedstock

• The primary raw materials used for paperboard production include wood chips, residual material from softwood dimensional lumber production, and recovered paper or paperboard products.

• Additional inputs include chemicals for cooking liquors, additives such as starch and aluminum sulfate, sizing agents such as natural resins or synthetic sizing, and pigments and latex used for coatings (StoraEnso 2008).


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Pulp Conversion

• First, the wood is broken down into cellulose fibers by chemically dissolving the lignin that binds the wood fibers together (chemical pulping).

• After which, the slue is bleached, which serves to remove additional lignin from the fiber and lightens the pulp.

• Common bleaching chemicals include chlorine dioxide and to alesser degree oxygen, ozone, hydrogen peroxide and enzymes such as xylanase.


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Paper Making • The papermaking process begins at the wet end of the

papermaking machine where a layer of furnish consisting of about 99% water and 1% pulped fiber is dispersed evenly onto a continuously moving wire screen.

• As the furnish moves through the process more and more water is removed and the paper is formed as it moves through a series of rollers.

• Once the fiber mat is established on the screen, the remainder of the process smoothes the paper through calendaring and removes water using vacuums and presses, followed by final drying.


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Environmental Considerations

• Pulp and papermaking requires large inputs of water, energy, chemicals, and wood resources, and produces various wastes and emissions that must be controlled or treated (U.S. DOE 2005).

• Impacts on the environment can come from toxic and hazardous chemicals in air and water emissions, thermal and wastewater loading to natural waterways, odor–causing chemicals, air pollutants from combustion, and solid wastes (U.S. DOE 2005).


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Monomer Production Process

• Both natural gas and petroleum are extracted from the earth for the production of plastic.

• After extraction, these materials are transported to a gas processing plant or oil refinery where they are mixed with naphtha prior to the steam cracking process.

• The extreme heat used in the process reduces or ‘cracks’ the molecule size of the natural gas or oil, forming lighter and more reactive hydrocarbons like ethylene and other monomers such as propylene.


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Polymer Production Process, Ex: PP• PP is typically formed in either liquid or gas phase propylene

reactions. • Liquid propylene polymerization is carried out at pressure of

about 365-510 psi and a temperature of 140-175 F. The process requires a reactor for the propylene monomer, hydrogen, and catalyst.

• As the propylene monomer flows through the reactor, about 50% of it reacts and becomes polypropylene polymer.

• The unreacted propylene is recycled back to the reactor. The polypropylene polymer is fed into a pelletizer to form pellets.


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Environmental Considerations

• Oil and natural gas are the primary sources of energy for resin production; however, 10-15% of energy required for resin production is embedded in the polymer available for later recovery.

• Carbon dioxide, methane and nitrous oxide are the major greenhouse gases emitted during resin production; however, over 75% of C02 emissions are related to fossil fuel use (Franklin 2007).


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HDPE LDPE LLDPE PP PET GPPS HIPS PVC ABS Fiber-Based Packaging Materials

0

2

4

6

8

10

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Energy Required for Production of Common Packaging Polymers and Fiber-Based Packaging Materials (Franklin Associates, a Division of ERG, 2007 & U.S. DOE, 2005)

Material Type

Mill

ion

Btu

per 1

,000

lbs

of m

ater

ial p

rodu

ced


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PET HDPE PVC LDPE PP PS PLA0

500

1000

1500

2000

2500

3000

Overall Emissions/Waste Generated in Polymer Production(Franklin 2007. Brown and Cole 1993, APME 2005/6 & NAPCOR 2006)

Air EmissionsWater DischargesSolid Waste

Polymer Type

Lbs

of w

aste

gen

erat

ed p

er 1

,000

lbs

of re

sin

prod

uced


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Multipl

e with

in SIC

Cod

e 26*

Paperb

oard

Mills

Paper

Mills

Pulp M

ills

Paper

Coated

& La

minated

, nec

*

Paper

Coated

and L

amina

ted, P

acka

ging

Folding

Pap

erboa

rd Box

es

Conve

rted P

aper

Produc

ts, ne

c*

Sanita

ry Foo

d Con

taine

rs

Bags:

Plastic

, Lam

inated

, & C

oated

Fiber C

ans,

Drums &

Sim

ilar P

roduc

ts

Bags:

Uncoa

ted P

aper

& Mult

iwall

Corrug

ated &

Soli

d Fibe

r Box

es

Sanita

ry Pap

er Prod

ucts

0

10,000,000

20,000,000

30,000,000

40,000,000

50,000,000

60,000,000

70,000,000

80,000,000

90,000,000

100,000,000

TRI Data: Pulp and Paper Production Air Emissions and Surface Water Discharges(U.S. EPA 1996)

Total Air EmissionsSurface Water Discharges

Industry

Lbs

of E

mis

sion

s/Di

scha

rges


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Container and Packaging MSW Data, 2007 (U.S. EPA 2008)

Paper & Paperboard52%

Plastic17%

Glass15%

Wood11%

Steel3%

Aluminum 2%

Paper & PaperboardPlasticGlassWoodSteelAluminum


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Container and Packaging % Recovery, (US EPA 2008)


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Paper vs. Plastic COMPASS LCACS-002 plastic: 36.854 g of Polyethylene Terephthalate (PET) converted using Thermoforming with Calendering

CS-002 corrugated: 96.544 g of Corrugated converted using Production of Corrugated Container


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We are REALLY excited to talk paper vs. plastic!

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